Shared-Semiconductor Bank Pattern for Simpler LED Display Fabrication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current display device manufacturing processes are costly due to the separate formation of light emitting elements and partition walls, which increases complexity and reduces efficiency.
Innovation Solution
A display device and manufacturing method where the light emitting element and partition wall are formed simultaneously using a shared semiconductor material structure, with a bank pattern and light emitting element comprising the same material, and a connection part that includes different semiconductor types, allowing for concurrent etching to create both elements in a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light emitting elements and partition walls are formed separately, then each element can be optimized independently, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent merges the formation of light emitting elements and partition walls into a single simultaneous process. Both structures are formed from the same semiconductor material layer through a unified etching process, eliminating the need for separate fabrication steps. This reduces process complexity and manufacturing costs while maintaining the functional integrity of both elements.
Solution Approach 2:
The semiconductor material layer serves multiple functions: it forms both the light emitting elements and the partition walls. The material layer is patterned to create different structures (light emitting elements in first areas, partition walls in second areas) from the same source material, achieving multi-functionality and reducing the number of material deposition steps required.
2Productivity
If light emitting elements and partition walls are formed simultaneously, then manufacturing efficiency increases, but precise control of each element's dimensions becomes difficult
Solution Approach 1:
The semiconductor material layer is divided into different regions with distinct patterns: first areas for light emitting elements and second areas for partition walls. Different etching conditions (etchant types, etching depths, etching times) are applied to different areas to achieve precise dimensional control of each element type simultaneously, maintaining manufacturing precision while improving efficiency.
Solution Approach 2:
Different etching parameters are applied locally to different areas of the semiconductor material layer. First areas undergo etching with parameters optimized for light emitting element dimensions, while second areas undergo etching with parameters optimized for partition wall dimensions. This local differentiation of etching quality ensures precise dimensional control for each element type despite simultaneous formation.
3Reliability
If separate processes are used for light emitting elements and partition walls, then each element achieves optimal properties, but process cost increases
Solution Approach 1:
The patent combines multiple fabrication processes into one simultaneous operation. The semiconductor material layer is patterned and etched in a unified process to create both light emitting elements and partition walls, reducing the total number of process steps, equipment usage, and manufacturing time, thereby lowering process costs while maintaining element optimization.
Solution Approach 2:
The patent utilizes parameter changes in the etching process (etchant concentration, temperature, etching time, etching power) to achieve optimal properties for different element types within a single process. By dynamically adjusting etching parameters for different areas, the patent maintains element performance optimization while reducing overall process cost through process integration.
Data Source
AI summary
A display device includes a substrate, and a display element part on the substrate, and including a light emitting element configured to emit light in a display direction, and a bank pattern that protrudes in the display direction, wherein the bank pattern and the light emitting element include a same material.